General Guidelines For T008-Design

TARA AEROSPACE SYSTEMS LIMITED
Work Instruction/Procedure
Title:-
Tool Designing and Fabrication Guidelines for Form Blocks
Document
Number
FORM BLOCK GENERAL GUIDELINES
Revision
Number
02
Effective Date
08th July 2014
Revision
Date
17th January 2015
1.0 SCOPE: General Guidelines for designing and fabrication of Form Blocks.
1.1 ABBREVIATIONS USED:
FBT
Form Block Template
T358 -
Flat Pattern code
T008 -
Form Block code
T005 -
Form Block Templates code
Ref
Refer
Fig
Figure
Rms -
Root Mean Square
Al
Aluminium
Eg.
Example
Stk.
Stock
Kg
Kilograms
mm -
Millimetres
O.D. -
Outer Diameter
Page 1 of 24
Title:-
2.0 FORM BLOCK DESIGN

2.1
Inputs
Part Model, Flat Pattern (Tool code-T358), and Process for the
component (Either in OP Sketches or in TDO Formats).
Note: Make sure that updated Revision number of part model and flat pattern
has been considered while designing form block
2.2
Design Considerations
2.2.1 Process Study
Before starting any form block design process related to the respective
Component should be studied by designer as listed below
No of stages in which component is formed.
Material of the component.
In which temper condition the forming is taking place.
Flange formation given in Flat pattern is UP or DOWN
which in turn should be in line with ENG DWG requirement, if
any flat view is given in drawing.
Tolerances of the component.
Feasibility of the form block in the machine decided by process.
Note: If process can be optimised, it has to be discussed in TRB (Tool
Review board) whether it is valid or not and same to be
Communicated to respective stake holders through TRB format.
2.2.2 BOTTOM BLOCK
Form block mainly has a bottom and top blocks between which the
Component is placed. The following are the design considerations for
Bottom block.
The important aspect to be considered while designing bottom block is to
how the component has to be formed i.e. whether a female block is to be
Page 2 of 24
Title:-
designed or a male block to be designed as bottom block.

For Example:
Female Bottom Block:
Male Bottom block:
Depending on the component features even male and female combination

should be used where mostly the female block would be as bottom block.
Page 3 of 24
Title:-
2.2.2.1
Web:
Web is the core material in the component which is not exposed to

the plactic deformation and which is taken as base for forming.
Choosing the web is an important aspect while designing the
female die as a bottom block. Generally the straight portion in the
component which is having the maximum area is taken as web.
Page 4 of 24
Title:-
2.2.2.2 Multiple Formings in the same stage:

Depending on part configuration if the multiple bends are there in
the component then the bottom block should be designed in such a
way that the bend which gets formed at first should not effect the
formation of the other flange.
In the above example if a female bottom block is to be designed

taking web as shown in above figure as base, formation of Flange-1
will effect the formation of Cavity as shown above.
2.2.2.3
Lug Positions in bottom block
Form block should have same lug positions (location holes) mentioned in
Flat patterns. Not only the positions but diameter of hole in the lug
mentioned in the flat pattern should also be retained while deciding the
locating hole positions in form block.
The accuracy of the locating hole positions should be with in -0.050mm to
+0.050mm. The machining tolerances of the form block should be
minimum of 1/3 of component tolerances.
Optimising the Tooling lugs
Usage of the tooling holes in the component web (If any) will reduce the
number of tooling lugs in the flat pattern and avoids trimming of lugs after
forming.
Page 5 of 24
Title:-
In the above example instead of adding two lugs for forming the
flanges having contour tooling holes can be used which
optimises the tooling lugs.
2.2.2.4
Diameter of Locating Lug holes
Diameter of the lug holes has to be decided such that the

machining inaccuracies of flat pattern has to be accommodated in
the form block. Before deciding the diameter of the pin designer
should cross verify the tolerances in flange width, bend angle and \
bend radius.
For example: If the component tolerances are 0.030 and 3-Axis
Routing machines in which flat patterns are routed in TSAL has an
accuracy of 0.005 both in position and diameter so the diameter of
the pins should be hole diameter mentioned in the flat pattern0.005.
The holes drilled in the bottom block should be reamed to H7
tolerance for what nominal value mentioned in the bottom block and
should have sliding fit with the locating pins (Mushroom headed
Page 6 of 24
Title:-
pins)
Two different diameters of the holes to be drilled in bottom block for
Fool proofing(Component can only be placed in one direction).
Table-1 shows different diameters used based on the length of the
component.
Table - 1
Length of component
<8"(200mm)
>8"(200mm)
2.2.2.5
Diameters of holes
Dia-1
Dia-2
0.1285"(3.26m
0.1875"(4.76m
m)
m)
0.1575"(4mm)
0.2362"(6mm)
Profile Cut
Profile cut to be provided as per sheet thickness on top face of the

bottom block for only the female tools. Maintain 2mm (0.078) offset
from part profile as per Flat pattern (Ref Figure 2).
2mm offset based on part

profile, step height should be
equal to thickness
Page 7 of 24
Title:-
If the step is not provided the rubber applies the pressure on the
web in female blocks and doesnt allow the material to flow into the
cavity of female block.
If the form block is made of Aluminium alloy a plastic film to be used
on the top of the bottom block to avoid friction between two
materials and thus allowing material to flow freely as shown in
below.
2.2.2.6
Spring Back
The tendency of the material to retain its original shape is spring

back. Spring back occurs when the component tries to pull back
after forming. For example if the flange in any sheet metal
component has to be formed to 90 degrees after subjected to a
load it might not result in 90degree bend instead it might lead to
less than 90degree bend. The form block should be designed in
such a way that it accommodates the spring back as shown
below.
Page 8 of 24
Title:-
The spring back value depends on type of material and temper

condition of component, pressure applied the values of spring
back provided in annexure-1.
The higher the forming pressure, the more uniform the results
obtained.
Spring back in the form block should start from the mold line as
shown in figure
Page 9 of 24
Title:-
2.2.2.7
Alignment Holes
The alignment holes in the bottom block ensure the alignment of top and the
bottom block. When the load is applied on the block from top these pins helps
the top block not to disturb its position with respect to bottom block.
Generally the lug position holes are used as dual purpose i.e for aligning the
component on bottom block and for aligning the top plate and bottom block.
If the component has contour in the web then alignment holes would be given
separately which should be press fitted in bottom block as shown in figure.
Page 10 of 24
Title:-
Note: All the holes in the bottom block should be thru and thru if separate
alignment pins are given so that the pins can be removed very easily.
2.2.2.8
Bend Radius
The corner radius in the bottom block where bend takes place should be
equal to that of the bend radius of the component.
Page 11 of 24
Title:-
For the components having multiple bends or where the distance

between bend lines of flanges is less than two times bend radius of
the component the bend radius is to be considered at LMC
condition i.e. least material condition.
2.2.2.9
Height of the bottom block
Height of the bottom block should be 5mm more than maximum flange height
or Minimum 25mm (1). Height of the top block should be 6mm (0.23) to
12mm (0.5mm). Use standard stock thicknesses (25mm, 35mm, 45mm, etc.).
(Refer figure 4)
Handling the form block in the shop floor should be considered while deciding
the height of the form block.
uld be 5mm more than max flange height. Flange height maintaining standard stock thickness
Page 12 of 24
Title:-
2.2.2.10 Stability of the bottom block

Form blocks 35mm (1.5) in cross sectional width, or narrower, should be given step (L
or T) for stability (Ref Figure 5).
L-Step for narrow width

Form Block
T-step for narrow width
2.2.2.11 No sharp Corners

No sharp corners should be present in the bottom block. Sharp
edges should have a corner of R 0.125 to R 0.5 depending on
length of the bottom block.
Higher the radius on the top plate lesser would be the pressure
on rubber by diaphragm of the machine.
2.2.2.12 Weight Optimization

Weight of the form block can be optimised by choosing correct
Page 13 of 24
Title:-
length, width and height of the form block (Bottom block and
top plate). Some important aspects to be considered for weight
Optimization.
1. Cut-outs to be made at the bottom of the bottom blocks to
reduce the weights if weight is greater than 15Kgs. These
cut-outs can be shown in design i.e 3D model of bottom
blocks or instruction can be given to the fabricator to make
cut-outs. Pocket width should not be more than 200mm (8)
and the thickness at the pocket area should be a minimum
of 15mm (0.6).
2. The thickness of the bottom block should be 5mm more
than the maximum flange height. The length and width of
the bottom block should not be more than 10mm from the
from the part boundary including the tooling lugs.
3. Thickness of the top plate should be 6mm with the 3mm
corner radius on all the edges.
4. If the length of the form block is more than 1000mm (40)
then the material of the form block should be taken as either
hylam wood or job rock since the density is half of AL alloy.
2.2.2.13 Lifting mechanisms

If the weight of the form block is more than 15Kgs,
lifting mechanism has to be provided in the form
blocks.
Page 14 of 24
Title:-
Other than slots in the bottom blocks hinges can be

provided so that it can be easy to lift the form block
and place in tray of rubber press machine.
2.2.2.14 Lightning hole

Lightening holes are generally given in the web of the
component as shown below
For forming lightening holes the following parameters to be

Considered
1. Bottom Block: For forming the lightening holes the following
pockets has to be created in the bottom blocks as shown
below depending on the part configuration.
The distance between the highest point of the lightening hole
in the component and the Surface A shown above has to
be minimum of 5mm (0.2).
Page 15 of 24
Title:-
2. Relief in top plate: Relief to be given in the top plate so that

rubber can be flow into the pocket of the bottom block and
form the lightening hole. The relief should be minimum of
2mm from the end of the bend radius line in the component.
3. Top punch: for the lightening holes which are not open at
one end require punch in line with the top plate so that
formation would be accurate.
Page 16 of 24
Title:-
4. Spring Back: Generally the spring back given for lightening

holes would be twice of the spring back given for open
ended flanges shown in table
Page 17 of 24
Title:-
2.2.3 Top plate Design

2.2.3.1
No sharp Corners
No sharp corners should be present on the top plate. Sharp

edges should have a corner of R 0.125 to R 0.5 depending on
length of the top plate.
Radius to be provided for all top edges of top plate
2.2.3.2
Clearance holes in top plate
All the component locating holes and alignment holes(If any) in

the bottom block should have a clearance holes (Thru Holes) in
the top plate and the diameter of the holes in the top plate
should be 0.004 more than the diameter of that in bottom block.
2.2.3.3
Material and machining tolerances of Top and

bottom blocks
Material of bottom block should be decided based on
the length and width, material of the component. For
all aluminium alloy components the bottom block
Page 18 of 24
Title:-
should be fabricated with aluminium alloy which is

equally or more harder than the component.
For example if the component material is Al alloy 2024
T6, then bottom block should be fabricated with AL
6064 T6 material which is harder than AL 2024.
Note: AL 6064 T6 is readily available in the market.
The machining accuracies of the form block is also
based on the component tolerances i.e tolerances on
the flange angle, web length and width etc. If the
component tolerances are 0.030 then the form
blocks should be machined with 1/3rd of component
tolerance i.e. 0.010. Flatness, parallelism tolerances
should be 0.005.
If the form block size is more than 1meter it is
preferred to go with Hylam wood.
2.2.3.4 Locating holes in top plate
Top plate Locating holes should be fool proof. The projection of the top plate
locating pins in the bottom block is 5mm (0.196) to 6mm (0.236) (Ref Figure
6).
Locating pins for part
should be protruded 3
to 4 mm
2.2.3.5 Set Back

Setback distance is the offset distance from End of the radius line to outer
face of the top block. If this distance is more it might create damage the
component while doing hand straightening. Set Back Distance should be 2mm
Page 19 of 24
Title:-
(0.098) from end of the radius line in bottom line for the top plate side profile
(Ref Figure 9)
2.2.3.6 Weight of top plate

The weight of the top plate is dependent on thickness of top
plate which should be 6mm unless any steps in the web
portion of the component.
Set Back Distance for Top Plate
Page 20 of 24
Title:-
Spring Back table
Page 21 of 24
Title:-
Page 22 of 24
Title:-
List of Records
Sr
no
Record
Description
Format No
Retentio
n Period
Retention
method
Disposal
method
Responsibili
ty
List of Documents
Sr
no
Document
Description
Document No
Retent
ion
Period
Retention
method
Disposal
method
Responsibili
ty
Revision Record
Effective
Page
Issue
/ Rev
Date
13-29S
01
17-1-2015
Prepared By & Date
Prepared
Approved by
by
LOVEY
SANAT
Checked By & Date
Revision Details
ANNEXURE1 ADDED
Approved By & Date
Page 23 of 24
Title:-
PROPRIETARY NOTICE: This document is Proprietary Data of the Tara Aerospace Systems Ltd. The information
contained herein shall not be copied or reproduced, used or disclosed to others without the authorization of Tara
Aerospace Systems Ltd. Uncontrolled if Printed
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TARA AEROSPACE SYSTEMS LIMITED

Tool Designing and Fabrication Guidelines for Form Blocks

FORM BLOCK GENERAL GUIDELINES

08th July 2014

17th January 2015

Form Block Template

Flat Pattern code

Form Block code

Form Block Templates code

Root Mean Square

TARA AEROSPACE SYSTEMS LIMITED

Tool Designing and Fabrication Guidelines for Form Blocks

2.0 FORM BLOCK DESIGN

TARA AEROSPACE SYSTEMS LIMITED

Tool Designing and Fabrication Guidelines for Form Blocks

designed or a male block to be designed as bottom block.

Male Bottom block:

Depending on the component features even male and female combination

TARA AEROSPACE SYSTEMS LIMITED

Tool Designing and Fabrication Guidelines for Form Blocks

Web is the core material in the component which is not exposed to

TARA AEROSPACE SYSTEMS LIMITED

Tool Designing and Fabrication Guidelines for Form Blocks

2.2.2.2 Multiple Formings in the same stage:

In the above example if a female bottom block is to be designed

Lug Positions in bottom block

TARA AEROSPACE SYSTEMS LIMITED

Tool Designing and Fabrication Guidelines for Form Blocks

Diameter of Locating Lug holes

Diameter of the lug holes has to be decided such that the

TARA AEROSPACE SYSTEMS LIMITED

Tool Designing and Fabrication Guidelines for Form Blocks

Profile cut to be provided as per sheet thickness on top face of the

2mm offset based on part

TARA AEROSPACE SYSTEMS LIMITED

Tool Designing and Fabrication Guidelines for Form Blocks

The tendency of the material to retain its original shape is spring

TARA AEROSPACE SYSTEMS LIMITED

Tool Designing and Fabrication Guidelines for Form Blocks

The spring back value depends on type of material and temper

TARA AEROSPACE SYSTEMS LIMITED

Tool Designing and Fabrication Guidelines for Form Blocks

TARA AEROSPACE SYSTEMS LIMITED

Tool Designing and Fabrication Guidelines for Form Blocks

TARA AEROSPACE SYSTEMS LIMITED

Tool Designing and Fabrication Guidelines for Form Blocks

For the components having multiple bends or where the distance

Height of the bottom block

TARA AEROSPACE SYSTEMS LIMITED

Tool Designing and Fabrication Guidelines for Form Blocks

2.2.2.10 Stability of the bottom block

L-Step for narrow width

T-step for narrow width

2.2.2.11 No sharp Corners

2.2.2.12 Weight Optimization

TARA AEROSPACE SYSTEMS LIMITED

Tool Designing and Fabrication Guidelines for Form Blocks

2.2.2.13 Lifting mechanisms

TARA AEROSPACE SYSTEMS LIMITED

Tool Designing and Fabrication Guidelines for Form Blocks

Other than slots in the bottom blocks hinges can be

2.2.2.14 Lightning hole

For forming lightening holes the following parameters to be